Building the Future: Solving Problems with Industrial Robotics and Collaboration in Plastics Manufacturing

The plastics industry faces significant challenges in remaining competitive in the market. Some of these challenges can be effectively addressed through the integration of industrial and collaborative robotics. This article discusses the main issues and future prospects for operations management in this lively sector, focusing on how robotics is transforming production processes to address these challenges.

In the hectic environment of a plastics manufacturing facility, keeping production running smoothly without disruptions is a monumental task. For example, if a machine breaks down or an operator calls in ailing, the entire production line can experience delays, affecting the facility’s ability to meet delivery deadlines. This is where industrial robots shine. Robots that can work tirelessly around the clock ensure consistent production output while minimizing disruptions. For example, integrating robot arms that perform repetitive tasks, such as moving mold parts between processing stations, can prevent wasted time and enable faster production turnarounds, directly addressing inefficiencies and streamlining workflow.

The shortage of skilled labor in the industry is another major obstacle. Consider a scenario where a high-demand order has been received, but the plant is short-staffed due to a lack of skilled workers. Training modern workers in time-sensitive situations isn’t always feasible. Robots can fill these gaps by taking on repetitive and threatening tasks, such as handling sizzling plastic parts directly from injection molding machines. This frees up human workers to engage in higher-value-added activities, such as process optimization and innovative problem-solving. Imagine a collaborative robot (cobot) working alongside human operators to manage material handling, effectively creating a partnership that maximizes human talent while the robots handle the mundane work.

Ensuring that every product meets stringent quality standards can be a daunting challenge for human operators, especially during long shifts when fatigue sets in. For example, manual quality checks can miss diminutive defects, leading to inconsistent product batches. Robotic systems provide unparalleled precision and consistency. Industrial robots equipped with advanced vision systems can perform detailed quality checks in real time during the manufacturing process. For example, a robot can monitor injection molding processes and immediately identify defects, ensuring that only the highest quality products advance to the next stage of production. This level of accuracy not only reduces waste and rework, but also ensures that you are consistently delivering high-quality products to your customers.

The risk of injury in plastics manufacturing is a major concern, as workers are often exposed to high temperatures, acute objects, and weighty equipment. For example, operators manually loading and unloading parts or inserts into injection molding machines can cause earnest injuries. By deploying robots to handle threatening and physically demanding tasks, this risk can be dramatically reduced. Robots can autonomously manage the loading and unloading of parts from hot-melt molding machines, keeping human operators secure and focusing on supervisory roles rather than direct physical involvement. This change not only improves workplace safety, but also reduces costs associated with ailing leave and accident claims.

Unforeseen equipment failures can bring an entire production line to a halt, leading to costly downtime. Suppose a critical molding machine breaks down during peak production hours; delays can be costly and disruptive. Robotics makes predictive maintenance a reality. Robots equipped with IoT sensors can continuously monitor machine health, predicting and alerting maintenance teams to potential failures before they occur. This enables timely interventions to prevent failures. In addition, the robotic machines themselves are designed for high reliability and minimal maintenance, further reducing operational disruptions.

Integrating robotics into plastics manufacturing is revolutionizing production lines by increasing efficiency, consistency, and safety. Robots can be used at various stages of the manufacturing process, from machine tending to finishing, offering significant improvements in productivity and quality.

• Machine operation: Robots can load and unload injection molding machines, reducing the risk of worker injury and increasing production consistency.
• Insert molding: Robots can efficiently perform tasks such as adding inserts to molds and loading them into machines. They are faster, which shortens cycle times and increases profitability.
• Overmolding: Six-axis robots can automate the injection molding process, reducing labor and assembly costs while ensuring product quality. They also speed up production, reducing cycle times and increasing profitability.
• Labeling in the form of: Robots can perform precise in-mold labeling, increasing the efficiency and accuracy of the process.
• Post-processing: Robots can perform a variety of post-processing tasks such as inspection, testing and sizzling stamping of molded plastic parts.

A global Tier 1 automotive supplier approached our DIY Official Integrator looking to optimize their overmolding process, specifically involving the overmolding of an EPDM plastic insert. The customer’s existing setup required 12 operators to meet cycle times and annual production volumes.

The customer needed precise edge cuts to within a few thousandths of an inch. This task required a level of craftsmanship that was hard to consistently and efficiently maintain by hand. The goal was to reduce the reliance on a enormous number of operators while achieving the required precision and improving overall efficiency.

1. Production delays and inefficiencies: Relying on 12 operators led to regular delays due to manual errors and the need for extreme precision, slowing down the production process.
2. Staff constraints and skills shortages: High employee turnover and the need to continually recruit and train qualified operators were costly and time-consuming.
3. Maintaining quality and consistency: Hand cutting did not provide the required precision, leading to quality issues and batch-to-batch non-consistency.
4. Workplace Safety and Injuries: Knife operators were exposed to significant risk of injury, contributing to higher medical costs and lost workdays.
5. Unplanned downtime and maintenance challenges: The manual nature of the process resulted in regular unplanned downtime due to operator fatigue and equipment maintenance issues.

Our Official Integrator implemented a solution using two Comet 44 robotic cells equipped with laser cutting technology. This automated the precision cutting task, significantly reducing the need for manual intervention.

1. Optimization of production efficiency and timeliness: Automation of the cutting process using robots has eliminated manual errors and significantly reduced cycle times, resulting in a smoother and more effective production flow.
2. Supporting employees and improving their skills: The implementation of robotic stations reduced the need to employ 6 operators, thus minimizing problems related to high staff turnover, recruitment and training costs.
3. Ensuring high quality and consistency: Laser cutting robots provided unprecedented precision and repeatability, achieving an overall equipment effectiveness (OEE) of 98%. A level of quality previously unattainable with manual labor was maintained this time.
4. Promoting safety and well-being in the workplace: When robots take over cutting tasks, operators no longer need to operate knives, which significantly reduces the risk of injuries and musculoskeletal problems.
5. Maximize uptime and streamline maintenance: Reliable operation of robotic cells minimized unplanned downtime and reduced maintenance issues, ensuring continuous production.

An initial investment of $300,000 for 2 robotic laser trimming cells resulted in an estimated savings of $900,000 over three years. This significant return on investment was achieved through reduced labor costs, improved quality, and increased operational efficiency.

The integration of industrial and collaborative robotics in the plastics industry offers significant opportunities to improve efficiency, quality, and competitiveness. However, it also presents challenges that operations managers must address, including initial capital costs, workforce adaptation, and ongoing maintenance.

As the robotics market continues to evolve, manufacturers should consider leveraging automation in their plastic injection molding processes to keep up with rapidly changing market demands and maintain a competitive advantage.

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